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FAST & EASY MACHINE SETUP PROJECT ( SIMPLY EXCHANGE OF FİXTURE-SEF ) &

6 Sigma. FAST & EASY MACHINE SETUP PROJECT ( SIMPLY EXCHANGE OF FİXTURE-SEF ) & PILOT APPLICATION OF 4 AX MILLING MACHINE. PROJECT SUMMARY. 6 Sigma. Project Y Project Description Project Objectives/Goals Customer/GE Benefits Financial Benefits Y Owner MBB/BB. - PRODUCTION.

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FAST & EASY MACHINE SETUP PROJECT ( SIMPLY EXCHANGE OF FİXTURE-SEF ) &

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  1. 6 Sigma FAST & EASY MACHINE SETUPPROJECT(SIMPLY EXCHANGE OF FİXTURE-SEF ) & PILOTAPPLICATION OF 4 AX MILLING MACHINE

  2. PROJECT SUMMARY 6 Sigma Project Y Project Description Project Objectives/Goals Customer/GE Benefits Financial Benefits Y Owner MBB/BB - PRODUCTION SEF-Simply Exchange of Fixture and Pilot Application on 4 Axis Machine Production Flexibility and Decrease Setup Time • Reduced cycle time/improve capacity

  3. MMEASURE ANALYZE IMPROVE CONTROL Project Title: Create an order to get tool, fixture, gage, and cnc program in digitam system Project ID#: - Six Sigma Project Status Status as of: Measure-Analyze Expected Completion Date: Project Leader: Y Owner: Project Y: PRODUCTIVITY Financial Benefits: Team Members Project Statement & Benefits NameFunction 1- 2- 3- 4- 5- 6- 7- 8- BLACK BELT BLACK BELT SUPR.TOOL GREENBELT GREENBELT SUPERVISOR . SUPERVISOR TOOL STOCKKEEPER • Scope: • Goals & Objectives: Flexibility on production Decrease Setup Times • Benefits: Reduced cycle time / Improve capacity Status Next Steps • Accomplishments: Data gathering, fixture and Machine • Tools applied: • Significant findings: • Next steps: • Additional tool to be applied: Design system & • Help needed: Yes

  4. CTQ’s - Defect - Target 6 Sigma CTQ HIGH SET-UP TIME, NONFLEXIBLE SETUP Defect STANDARDISATION Target 25% DECREASE OF S/U TIME & MORE FLEXIBILITY

  5. 6 Sigma TABLE-1 MACHINE-FİXTURE & OPERATION DATAS

  6. 6 Sigma

  7. OPERATION & S/U TIME RELATIONSHIP 6 Sigma

  8. CAUSE AND EFFECT FASTENİNG MAT’L CARELESSNESS STANDARDIZATION FLEXIBLE CHANGING SHIFT FIXTURE CHIP CLEAN METHODS EQUIPMENT 6 Sigma OPERATOR TRAINING High S/U Hours

  9. WHY 4 AXIS MACHINE 6 Sigma • Capability of Holding up to 25” tools • Rotating Table & Machine Course • There is only one Milling Machine With this spesifications • Heavy & Large Fıxtures, • Because of small lot size Frequent Set-up Changıng, req. b GENERAL VIEW OF THE 4 AX MILLING MACHINE

  10. 6 Sigma • Flexible Set-up Requırements, Geometric Differencies of the Fixtures • Group Technology Appl. diffuculties DIFFERENT VIEWS FOR 4 AX MACHINE

  11. 6 Sigma • Due to 4 Axıs Milling Machıne Applıcatıon Results Wıll be Affected of Other Vertical-Horizontal and Multiple Axis Milling Machine Flexıbılıty Studıes... For This Reason ; 4 axis Milling Machine were Selected to the Pilot Applicatıon.

  12. FLOWCHART FOR SETUP 6 Sigma Fixture Handling from SRS Fixture Cleaning To the Machine Machine Placement T nut, Fastener Finding Setup Control Internal S/U Part positioning Fixture Fastening Part Handling External S/U

  13. 6 Sigma • WHY THE TIME IS INCREASING? • Dimensions and weights of the fixture • Fix. Geometries haven’t standart Shapes • Nonstandart Pın and Bolts slots & Holes • Used Nonstandart Bolts • Rotary Table Properties, • Parts have different Datum Systems (Point ,area etc.)For this reason, there are very complex shape fixtures, • Expanding fixtures • T-Nut and Fastening Elements Problems - Look for elements, Time requıred

  14. Workıng Procedures 6 Sigma • All Fixtures were layed out on Machine Rotary Table With Sub Plate. For this Reason Subplate Will be Designed & positioned with Pin-Bushing systems & Fastened to the fixture with Bolt-Nut As a Basement of Work;Fixtures will be fastened on machine as little as possible, No need positıonıng Fixtures and Machine datas are available; (Table-1)

  15. Workıng Procedures and troubles 6 Sigma Big Dimensions & Geometric Differencies and Datum Systems properties of Fixtures will be Controlled on Real/Right places Expanding Fixtures are some different Applications Requıred, Due to Set up reduction time works; • T-Nuts on the rotary table, • -Bolts,Nuts Eye bolts will be placed near of the Machine • These type of problems are caused increasing for Setup Times.

  16. 6 Sigma FIXTURES GENERAL VIEW OF FIXTURES

  17. 6 Sigma Workıng Procedures We are working on the; - Innovatıve and İmproved best Concepts Linear Bushing Systems One of the most important and innovative Equıpment are researching for Cleaning on the Machine Rotary Table Chips penetrated on the table, T-Nut channels, bolt holes and the other slots and holes. İnnovative cleaning, New easy cleaning Facility and Equıpments or; Chips may be holded without dropping These are researching for new innovation...

  18. 6 Sigma ROTARY TABLE and FİXTURE LAYOUT ON THE TABLE ROTARY TABLE and 5 DIFFERENT PARTS FIXTURES ON THE TABLE

  19. M39 Fixturing & Sub Plate section View 6 Sigma

  20. 6 Sigma M39 Fixture & Sub Plate Assy. AĞIRLIKLAR; FİKSTÜR;780 kg ALT TABLA; 289 kg.

  21. 6 Sigma General View for Sub Plate

  22. General View of SubPlate 6 Sigma GGG 60

  23. 6 Sigma LINEAR BUSHING SYSTEMS

  24. 6 Sigma

  25. procedure 6 Sigma • Machine datas, • Rotary table • Course • T NUT ChannelI • Fixturing Datas • Geometry & Dimensions • Holes • Fixturing systems (EXP, Datum systems etc.). • Define SEF systems • Designing Subplate • Pın-bushing Systems Selectıon • Design Pin-Bushing position of subplate-Fix. Assy • Define Positıon and Tolerances • Sub Plate properties • Weight • Sub plate Strength Calculatıon • Pin-Bushing stress analysis • Fixture Pin & Nut Stress Analysis • Sub Plate -Rotary Table Fastening Method. • T-Nut Channels • Sub plate/Rotary Table Assy Design

  26. Materials 6 Sigma SubPlate Material: GGG 60 - Spheroidal Cast Iron Weight; 285 Kg. TOTAL Max Load on Rotary Table; 1070Kg.

  27. 6 Sigma Important Issues • Subplate Dimensions and Position Tolerances (.0000-.0015) • Pın-Bushing Application and Fixtures thickness Differencies,For this reason Pin-bushing Position, • If using linear Bushing Systems, Big and heavy Fixtures will be damaged on roller Bushing. For this reason radial and axial loads and stress will be defined. • Subplate -fixture fasteners like Bolt, Nut, Pin, eye bolt stress analysis required

  28. SAVING • ALL PARTS HAVE 20 S/U /YEAR • MİN %25 SAVING • 30 HRS FOR M61 PARTS • 20 HRS FOR M39 PARTS • 20 HRS FOR M37 PARTS • 20 HRS FOR M52 PARTS • 16 HRS FOR L44815G01 PARTS • TOTALLY 100 HRS/YEAR FOR 4 AXIS MACHINE • 106*18=1908$ • FLEXIBLE SETUP AND OPERATOR SAVING • RELAX SETUP • APPROX % 50 SAVING FOR POSITIONING; NO NEED USE CLAMP, T-NUT etc. 5$ *25=125$ • OPERATOR ASSURANCE, SAFETY AND EASY SETUP

  29. 6 Sigma PROGRAM PLAN

  30. Six Sigma Project Scorecard 6 Sigma Improve Measure Control Analyze Understand Environment - Meet business leader - Establish key contacts - Tour process - Identify process owner - Identify team members Review Measure Phase - Champion comments - Update team / stakeholders Review Analyze Phase - Champion comments - Update team / stakeholders Review Improve Phase - Champion comments - Update team / stakeholders 10% Train Team on 6 sigma tools Train Team on 6 sigma tools Train Team on 6 sigma tools Issue Revised QCWIs / procedures where applicable Define Performance Objective for “Y” Review process map Develop new process flow 20% Bound the Project Revalidate Cause & Effect of X’s to Achieve Y’s Process Map Identify Variation Sources Screen Potential Causes Identify Root Causes of variation Train Team on 6 sigma tools 30% Create Product Tree Determine Process Capability Identify X’s - Cause & Effect Diagram Identify Customer Requirements - CTQ’s via QFD - Identify additional data Needs Implement Control System for Process Fixes Establish Operating Tolerances 40% Benchmark similar products and processes Identify Improvement Actions and Implementation Plan Identify Follow-up Action Plan and Individuals Responsible Create Process Map Coordinate with ITS for systems resources where applicable 50% Analyze Data - Apply Statistical Tools - Hypothesis Tests Develop Risk Assessment Risk Abatement Plan Identify Opportunities for Standardization Define performance standards - Gather / Pareto data - Review Historical data Obtain buy-in / support for improvement actions List Best Practices and Identify Lessons Learned 60% Define additional data needs Implement Improvements - - Identify opportunities to leverage improvements Develop Presentation - Review Team / MBB / Sponsor - Present results to Champions and Operational Leaders Evaluate measurement system - Gage R&R 70% Hand off project to Process Owner Collect & analyze data to validate improvement Establish Product Capability - Calculate DPU - Calculate Z st and Zlt 80% Develop Presentation - Review Team / MBB / Sponsor - Present results to Champions and Operational Leaders Communicate Improvements Develop Presentation - Review Team / MBB / Sponsor - Present results to Champions and Operational Leaders Develop Presentation - Review Team / MBB / Sponsor - Present results to Champions and Operational Leaders 90% Monitor process performance 100%

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